Recovering heat energy

ABSTRACT

Some embodiments of a generator system can be used with the working fluid in a Rankine cycle. For example, the generator system can be used in a Rankine cycle to recover heat from one of a number of commercial applications and to convert that heat energy into electrical energy. In particular embodiments, the generator system may include a turbine generator apparatus to generate electrical energy and a liquid separator arranged upstream of the turbine generator apparatus.

TECHNICAL FIELD

This document relates to the operation of a fluid expansion system,including some systems that comprise a turbine apparatus to generateenergy from gaseous fluid expansion.

BACKGROUND

A number of industrial processes create heat as a byproduct. In somecircumstances, this heat energy is considered “waste” heat that isdissipated to the environment in an effort to maintain the operatingtemperatures of the industrial process equipment. Exhausting orotherwise dissipating this “waste” heat generally hinders the recoveryof this heat energy for conversion into other useful forms of energy,such as electrical energy.

Some turbine generator systems have been used to generate electricalenergy from the rotational kinetic energy a turbine wheel. For example,the rotation of the turbine wheel can be used to rotate a permanentmagnet within a stator, which then generates electrical energy. Suchturbine generator systems use a compressed gas that is expanded duringthe flow over the turbine wheel, thereby causing the turbine wheel torotate. In some circumstances, the fluid flowing toward the turbinewheel can include “slugs” of liquid state fluid intermixed with thegaseous state fluid. The presence of liquid slugs in the working fluidcan reduce the efficiency of the turbine system.

SUMMARY

Some embodiments of a generator system can be used in a Rankine cycle torecover heat from one of a number of commercial applications and toconvert that heat energy into useable electrical energy. For example,the Rankine cycle may employ a working fluid that recovers heat from acommercial compressor interstage cooler or a commercial exhaustoxidizer. The heated and pressurized working fluid can then be directedto the generator system for generation of usable electrical energy. Inparticular embodiments, the generator system may include a turbinegenerator apparatus to generate electrical energy and a liquid separatorarranged upstream of the turbine generator apparatus. In suchcircumstances, the liquid separator can receive the heated andpressurized working fluid so as to separate a substantial portion of theliquid state droplets or slugs of working fluid from the gaseous stateworking fluid. The gaseous state working fluid can be passed to theturbine generator apparatus with the substantial portion of liquid statedroplets or slugs removed, thereby protecting the turbine generatorapparatus from damage caused by such liquid state working fluid.

In some embodiments, a method of using a turbine generator system mayinclude pumping a working fluid in a Rankine cycle from a low pressurereservoir toward at least one commercial compressor interstage cooler.The method may also include heating the working fluid from the heatenergy recovered from one or more compression stages of the commercialcompressor interstage cooler. At least a portion of the working fluidmay be pressurized and heated to a gaseous state. The method may furtherinclude directing the heated and pressurized working fluid toward aturbine generator apparatus. The turbine generator apparatus may includean inlet conduit to direct the working fluid toward a turbine wheel thatis rotatable in response to expansion of the working fluid. The methodmay also include generating electrical energy from the rotation of theturbine wheel. The turbine wheel may be coupled to a rotor of anelectrical energy generator that rotates within a stator of theelectrical energy generator.

In some embodiments, a method using a turbine generator system mayinclude pumping a working fluid in a Rankine cycle from a low pressurereservoir toward at least one commercial exhaust oxidizer. The methodmay also include heating the working fluid from the heat energyrecovered from the commercial exhaust oxidizer. At least a portion ofthe working fluid may be pressurized and heated to a gaseous state. Themethod may further include directing the heated and pressurized workingfluid toward a turbine generator apparatus. The turbine generatorapparatus may include an inlet conduit to direct the working fluidtoward a turbine wheel that is rotatable in response to expansion of theworking fluid. The method may also include generating electrical energyfrom the rotation of the turbine wheel. The turbine wheel may be coupledto a rotor of an electrical energy generator that rotates within astator of the electrical energy generator.

These and other embodiments described herein may provide one or more ofthe following advantages. First, some embodiments of a fluid expansionsystem may include a liquid separator arranged upstream of a turbinegenerator apparatus. The liquid separator may be configured to separateand remove a substantial portion of any liquid state droplets (or slugs)of working fluid that might otherwise pass into the turbine generatorapparatus 100. Because a substantial portion of any liquid-statedroplets or slugs are removed by the liquid separator, the turbinegenerator apparatus may be protected from erosion or damage caused bysuch liquid state working fluid.

Second, the fluid expansion system may be equipped with a dual controlvalve system that provides flow control during transient flowconditions, protection for the turbine generator apparatus, andefficient power output from the turbine generator apparatus. In somecases, first and second control valves may be mechanically coupled toone another so as to operate in unison, for example, by activation of asingle actuator device.

Third, the fluid expansion system can be used to recover waste heat fromindustrial applications and then to convert the recovered waste heatinto electrical energy. The heat energy can be recovered from anindustrial application in which heat is a byproduct, such as commercialexhaust oxidizers (e.g., a fan-induced draft heat source bypass system,a boiler system, or the like), refinery systems that produce heat,foundry systems, smelter systems, landfill flare gas and generatorexhaust, commercial compressor systems, food bakeries, and food orbeverage production systems. Furthermore, the heat energy can berecovered from geo-thermal heat sources and solar heat sources.

Fourth, some embodiments of the turbine generator apparatus may bearranged so that the fluid outflow to the outlet side of the turbinewheel is directed generally toward the rotor, the stator, or both (e.g.,toward a permanent magnet, toward generator components disposed aroundthe permanent magnet, or both). Such a configuration permits the fluidto provide heat dissipation to some components of an electricalgenerator device.

Fifth, some embodiments of the turbine generator apparatus may include aturbine wheel that is coupled to bearing supports on both the input sideand the outlet side of the turbine wheel, which provides a configurationfavorable to rotordynamics operation and lubrication. For example, onebearing support may be located adjacent to the input face of the turbinewheel, and a second bearing support may be located on the outlet sidebut axially spaced apart from the wheel outlet (e.g., not immediatelyadjacent to the turbine wheel outlet). Accordingly, the turbine wheelcan be supported in a non-cantilevered manner with bearing supports onboth the input side and the outlet side of the turbine wheel. Also, theturbine generator apparatus may be configured to provide service accessto the bearing supports without necessarily removing the turbine wheelor the rotor from the turbine generator casing.

Sixth, some embodiments of the turbine apparatus may include at leasttwo seals on opposing sides of the turbine wheel (e.g., at least oneseal on the input side and at least one seal on the outlet side). Theseseals may be part of subsystem that provides a thrust balance effect tothe turbine wheel during operation. In such circumstances, the thrustbalance provided by the subsystem can permit significant pressure ratioimplementations across the turbine wheel.

Seventh, some embodiments of the turbine generator apparatus can reducethe likelihood of leakage to or from the external environment. Forexample, if a portion of the working fluid diverges from the flow pathand seeps past the seal around the turbine wheel, the leaked fluid maymerely reenter the fluid flow path (rather than leaking outside of thefluid flow path and into the environment).

Eighth, some embodiments of the turbine generator apparatus can be usedin a Rankine Cycle, such as an organic Rankine Cycle, to generatekinetic energy from fluid expansion. Such kinetic energy can be used,for example, to generate electrical power. Other embodiments of theturbine generator apparatus may be configured for use in other fluidexpansion operations, for example, a Carnot cycle, a gas letdown system,a cryogenic expander system, or a process expansion system.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a fluid expansion system, in accordancewith some embodiments.

FIG. 2 is another perspective view of the fluid expansion system of FIG.1.

FIG. 3 is a side view of the fluid expansion system of FIG. 1.

FIG. 4 is a rear view of the fluid expansion system of FIG. 1.

FIG. 5 is a top view of the fluid expansion system of FIG. 1.

FIG. 6 is a front view of the fluid expansion system of FIG. 1

FIGS. 7A-B is a diagram of a fluid expansion system used in a Rankinecycle in accordance with some embodiments.

FIG. 8 is a quarter-sectional perspective view of a turbine generatorapparatus in accordance with some embodiments.

FIG. 9 is a cross-sectional view of the turbine generator apparatus ofFIG. 8.

FIG. 10 is a cross-section view of a portion of the turbine generatorapparatus of FIG. 8.

FIG. 11 is a diagram of a turbine generator apparatus used in a fluidexpansion system to generate electrical power, in accordance with someembodiments.

FIG. 12 is a diagram of a heat source for a working fluid in a Rankinecycle, in accordance with some embodiments.

FIG. 13 is a perspective view of fluid cycle to generate electricalenergy using a turbine generator apparatus, in accordance with someembodiments.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIGS. 1-4, a fluid expansion system 10 may include a numberof components that act upon a working fluid so as to generate kineticenergy from the expansion of the working fluid. In some embodiments, thefluid expansion system 10 can be part of a closed system, such as aRankine Cycle or the like, in which the pressurized and heated workingfluid is permitted to expand and release energy in a turbine generatorapparatus 100 (described below in connection with FIGS. 8-10). Suchkinetic energy can then be converted, for example, to electrical energythat is supplied to a power electronics system or to an electricallypowered machine. For example, the heated and pressurized working fluidmay enter the turbine generator apparatus 100 through an inlet conduit105 and thereafter expand as the fluid flows over a rotatable turbinewheel. Electrical energy can be generated from the rotation of theturbine wheel and then output from the fluid expansion system 10. Asdescribed in more detail below, the fluid expansion system 10 caninclude a liquid separator 40 arranged upstream of the turbine generatorapparatus 100. The liquid separator 40 may be configured to separate andremove a substantial portion of any liquid state droplets (or slugs) ofworking fluid that might otherwise pass into the turbine generatorapparatus 100.

Some embodiments of the fluid expansion system 10 include a reservoir 20that contains at least a portion of the working fluid in an expanded andcooled condition. For example, the working fluid disposed in thereservoir 20 may be in a liquid state after passing through a coolingstage of a Rankine cycle or the like. The reservoir 20 has an internalvolume that is accessed by a number of ports for the flow of workingfluid into and out of the reservoir 20. In this embodiment, thereservoir 20 is mounted to the package housing 12 of the system 10 sothat the reservoir 20 can be transported contemporaneously with theturbine generator apparatus 100. As shown in FIG. 1, the reservoir 20may comprise a vertically oriented tank. In some circumstances, thevertically oriented tank can be more space efficient. Also, thevertically oriented tank can be used to increase the amount of liquidstate working fluid that is arranged over the drain port of thereservoir 20. In other embodiments, the reservoir may comprise a fluidcontainer vessel having a different configuration, such as ahorizontally oriented tank that may be used, for example, to reduce theoverall height of the package housing 12.

It should be understood that the package housing 12 depicted in FIGS.1-4 may include outer panels that enclosed the components therein.Examples of such outer panels on the package housing 12 are shown anddescribed in connection with FIGS. 5-6. The outer panels are hidden fromview in FIGS. 1-4 to show the components of the fluid expansion system10.

Still referring to FIGS. 1-4, the fluid expansion system 10 may includea pump device 30 that is in fluid communication with the reservoir 20.The pump device 30 may be used to pressurize the working fluid and todirect the working fluid toward a heat source (described in more detailbelow). In this embodiment, the pump device 30 is mounted to the packagehousing 12 of the system 10 and is arranged below the reservoir 20 sothat the working fluid is gravity fed toward the pump device 30. Thepump device 30 may include a motor 35 that provides operational power tothe pump device. In these circumstances, rotation of the motor 35 drivesthe pump device 30 to force the working fluid toward the down streamcomponents. As described in more detail below in connection with FIGS.7A-B, the pump device 30 may direct the working fluid to flow toward aheat source 60, thereby causing the working fluid to be pressurized andheated. The heat source 60 may be arranged outside of the packagehousing 12 of the fluid expansion system 10. In such circumstances, theworking fluid may return to the fluid expansion system 10 via a conduitthat is connected to an inlet flow port (refer, for example, to theinput port adjacent the liquid separator 40 as shown in FIGS. 1-4).

Some embodiments of the fluid expansion system 10 also include a liquidseparator 40 arranged upstream of the turbine generator apparatus 100.As previously described, the turbine generator apparatus 100 receivesthe heated and pressurized working fluid so as to generate kineticenergy from the expansion of the working fluid therein. The turbinegenerator apparatus 100 may be configured to operate when the heated andpressurized working fluid is in a gaseous state. In such circumstances,the likelihood of erosion or other damage to the turbine generatorapparatus 100 may be increased when a portion of the working fluidincludes droplets or “slugs” of fluid in a liquid state. Also, theefficiency of the turbine generator apparatus 100 may be decreased whena portion of the working fluid includes droplets or slugs in a liquidstate. Accordingly, the liquid separator 40 may be arranged upstream ofthe turbine generator apparatus so as to separate and remove asubstantial portion of liquid state droplets or slugs of working fluidthat might otherwise pass into the turbine generator apparatus 100.

The liquid separator 40 may be in the form of a cyclone separatordevice, a coalescing membrane device, or the like. In the embodimentdepicted in FIGS. 1-4, the liquid separator 40 comprises a cycloneseparator device that mechanically spins the working fluid to therebycentrifugally separate some or all of the liquid state droplets ofworking fluid. For example, the liquid separator 40 may comprise acyclone separator device manufactured by R.P. Adams Company, Inc. ofTonawanda, N.Y.

The liquid separator may include a secondary reservoir 42 to which theseparated liquid-state droplets or slugs or working fluid are directed.The secondary reservoir 42 may be arranged below main body of the liquidseparator so that the separated liquid-state fluid can be gravity fedtoward the secondary reservoir 42. The secondary reservoir 42 may be influid communication with the previously described reservoir 20, therebypermitting the separated liquid-state droplets to return to the workingfluid contained in the reservoir 20. Accordingly, the liquid separator40 can be arranged upstream of the turbine generator apparatus 100 in amanner such that the gaseous state working fluid can be passed to theturbine generator apparatus 100 while a substantial portion of anyliquid-state droplets or slugs are removed and returned to the reservoir20.

Still referring to FIGS. 1-4, in some embodiments, the liquid separator40 may be arranged upstream of the turbine generator apparatus 100 suchthat the liquid separator 40 is in direct fluid communication with theturbine generator apparatus 100. In these circumstances, the heated andpressurized working fluid may be received by the separator inlet 45, andthe liquid separator 40 can act to remove a substantial portion of anyliquid-state droplets or slugs of working fluid (as previouslydescribed). The separator outlet 49 may be in direct fluid communicationwith the inlet 105 conduit of the turbine generator apparatus 100.Accordingly, in this embodiment, at least the gaseous state portion ofthe heated and pressurized working fluid is passed directly from theseparator outlet 45 to the inlet conduit 105 of the turbine generatorapparatus 100. Because a substantial portion of any liquid-statedroplets or slugs are removed by the liquid separator 40, the turbinegenerator apparatus 100 may be protected from damage caused by suchliquid state working fluid.

Furthermore, in these embodiments, the liquid separator 40 can serve asa reservoir volume to improve the system stability during transientconditions. For example, if the flow of the working fluid is initiatedtoward the turbine generator apparatus 100 before the working fluid hasbeen sufficiently heated and pressurized, a random burst of liquid-statefluid flow may pass towards the turbine generator apparatus 100. Theliquid separator 40 can serve as an accumulator device that protects theturbine generator apparatus 100 from such a burst of liquid-state fluidflow. Thus, in addition to reducing the likelihood of erosion damage tothe turbine generator apparatus 100, the liquid separator 40 may improvethe system stability during transient conditions.

Still referring to FIGS. 1-4, the heated and pressurized working fluidmay enter the turbine generator apparatus 100 through the inlet conduit105 and thereafter expand as the fluid flows over a rotatable turbinewheel (described below, for example, in connection with FIGS. 8-10). Inthis embodiment, the rotation of the turbine wheel in the turbinegenerator apparatus 100 is used to generate electrical energy that isthen output from the fluid expansion system 10. As shown in FIG. 3, theworking fluid may exit the turbine generator apparatus 100 through anoutlet conduit 109. In some embodiments, the expanded working fluid thatexits the turbine generator apparatus 100 may be directed to a coolingsource. For example, in those embodiments in which the fluid expansionsystem is part of a Rankine cycle, the expanded working fluid may bedirected to a condenser. Thereafter, the cooled and expanded workingfluid may be directed through a conduit to return to the reservoir 20(refer, for example, in FIG. 1). When the fluid expansion system 10 ispart of a closed loop Rankine cycle, as described in more detail below,some embodiments of the turbine generator apparatus 100 may serve as asingle stage turbine expander with variable speed capability.

Referring now to FIGS. 5-6, the fluid expansion system 10 can beconstructed so that a user can readily access a number of the systemcomponents. For example, as shown in FIG. 5, the package housing 12 ofthe fluid expansion system 10 may include a number of access panels 14that can be opened by a user to access the reservoir 20, the pump device30, the liquid separator 40, the turbine apparatus 100, and othercomponents. Accordingly, in some circumstances, the inspection andmaintenance of the fluid expansion system 10 can be performed withsubstantial disassembly. In addition, the fluid expansion system 10 mayinclude a control interface 15 (refer, for example, to FIG. 6) thatprovides the user with information on the performance and settings ofthe fluid expansion system. In some embodiments, the control interfacemay include a display screen, a number of indicator meters, or acombination thereof so that a user can monitor the operation of thefluid expansion system 10 and (in some circumstances) adjust anysettings or parameters of the system.

Furthermore, the fluid expansion system 10 can be constructed in amanner that provides simplified transportation to the desiredinstallation location. For example, the package housing 12 for the fluidexpansion system may have overall dimensions that permit transportthrough a standard double-door passage. In some embodiments, the packagehousing 12 of the fluid expansion system 10 may have a width W (refer,for example, to FIG. 6) that is less than about 72 inches, less thanabout 50 inches, and preferably about 48 inches or less. Also, in someembodiments, the package housing 12 of the fluid expansion system 10 mayhave a height H (refer, for example, to FIG. 6) that is less than about80 inches and preferably about 78 inches or less. As such, the fluidexpansion system 10 can be readily transported through a standarddouble-door passage to a desired installation location even if thatlocation is accessible only through a standard double-door passage(having a size of about 72 inches by about 80 inches). Optionally, thefluid expansion system 10 can be readily partially disassembled fortransport through a standard single-door passage (e.g., having a widthof about 36 inches). It should be understood from the description hereinthat the length L (refer, for example, to FIG. 3) of the packaginghousing 12 may be affected by a number of factors, such as the size ofthe turbine generator apparatus 100 and the size of the reservoir 20. Insome embodiments, the package housing 12 may have a length L of about180 inches or less, about 48 inches to about 150 inches, about 60 inchesto about 130 inches, and in this embodiment about 112 inches.

Referring now to FIGS. 7A-B, the fluid expansion system 10 may be partof a closed loop cycle 50, such as Rankine cycle, in which the heatedand pressurized working fluid is expanded in the turbine generatorapparatus 100. The Rankine cycle may comprise an organic Rankine cyclethat employs an engineered working fluid. The working fluid in such aRankine cycle may comprise a high molecular mass organic fluid that isselected to efficiently receive heat from relatively low temperatureheat sources. In particular circumstances, the turbine generatorapparatus 100 can be used to convert heat energy from a heat source intokinetic energy, which is then converted into electrical energy. Forexample, in some embodiments, the turbine generator apparatus 100 mayoutput electrical power in form of a 3-phase 60 Hz power signal at avoltage of about 400 VAC to about 480 VAC. Also, in some embodiments,the turbine generator apparatus 100 may be configured to provide anelectrical power output of about 2 MW or less, about 50 kW to about 1MW, and about 100 kW to about 300 kW, depending upon the heat source inthe cycle and other such factors.

As shown in FIG. 7A, the reservoir 20 of the fluid expansion system 10contains a portion of the working fluid for the closed loop cycle 50. Inthis embodiment, the working fluid disposed in the reservoir may be in aliquid state after being expanded and cooled. The pump device 30 isdriven by the motor 35 so as to pressurize the working fluid to toward aheat source 60. The pressurized working fluid is passed through aconduit toward the heat source so as to recover heat from the heatsource 60. In this embodiment, at least a portion of the heat energyfrom the heat source 60 is transferred to the working fluid using a heatexchanger 65. In other embodiments, the working fluid may flow directlyto the heat source 60 rather than receiving the heat from theintermediate heat exchanger 65. The heat source 60 may comprise, forexample, an industrial application in which heat is a byproduct. Theheat source 60 may comprise an industrial application including, but notlimited to, commercial exhaust oxidizers (e.g., a fan-induced draft heatsource bypass system, a boiler system, or the like), refinery systemsthat produce heat, foundry systems, smelter systems, landfill flare gasand generator exhaust, commercial compressor systems, food bakeries, andfood or beverage production systems. As such, the fluid expansion system10 can be used to recover waste heat from industrial applications andthen to convert the recovered waste heat into electrical energy.Furthermore, the heat energy can be recovered from geo-thermal heatsources and solar heat sources.

After the working fluid has received heat recovered from the heat source60, the heated and pressurized working fluid returns to the fluidexpansion system 10 and is directed toward the turbine generatorapparatus 100. The liquid separator 40 is arranged upstream of theturbine generator apparatus 100, so the heat and pressurized workingfluid passes through the liquid separator 40 before passing to theturbine generator apparatus 100. As previously described, the liquidseparator 40 may be arranged upstream of the turbine generator apparatusso as to separate and remove a substantial portion of any liquid statedroplets or slugs of working fluid that might otherwise pass into theturbine generator apparatus 100. In this embodiment, the liquidseparator 40 includes a secondary reservoir 42 to which the separatedliquid-state droplets or slugs or working fluid are directed. Thesecondary reservoir 42 may be in fluid communication with the previouslydescribed reservoir 20, thereby permitting the separated liquid-statedroplets to return to the working fluid contained in the reservoir 20.Because a substantial portion of any liquid-state droplets or slugs areremoved by the liquid separator 40, the turbine generator apparatus 100may be protected from damage caused by such liquid state working fluid.In addition, the liquid separator 40 may improve the system stabilityduring transient conditions (as previously described in connection withFIGS. 1-4).

Still referring to FIG. 7A, the gaseous state working fluid may enterthe turbine generator apparatus 100 after exiting the liquid separator40. The heat and pressurized working fluid can thereafter expand as thefluid flows over a rotatable turbine wheel (described below, forexample, in connection with FIGS. 8-10). In this embodiment, therotation of the turbine wheel in the turbine generator apparatus 100 isused to generate electrical energy that is then output from the fluidexpansion system 10. For example, in some embodiments, the rotation ofthe turbine wheel causes rotation of a rotor carrying a magnet device150 within an electric generator device 160 (refer, for example, toFIGS. 8-10). As described in more detail below, the electric generatordevice 160 may include electronic components used to configure andmodify the electrical power generated. For example, in some embodiments,the turbine generator apparatus 100 may output electrical power in formof a 3-phase 60 Hz power signal at a voltage of about 400 VAC to about480 VAC. The electrical components of the generator device 160 canregulate the electrical power output, thereby permitting the turbinegenerator apparatus 100 to serves as a single stage turbine expanderwith variable speed capability.

Referring to FIGS. 7A-B, the expanded working fluid that exits theturbine generator apparatus 100 (FIG. 7A) may be directed toward acooling source 80 (FIG. 7B). In this embodiment, the expanded workingfluid is passed through a conduit toward the cooling source 80 so as tocondense working fluid into a liquid state. Also in this embodiment, thecooling source 80 includes a condenser 85 that removes excess heat fromthe working fluid. In other embodiments, the working fluid may flowdirectly to the cooling source 80 (e.g., a cooling tower, a forced-airradiator system, or the like) rather than removing the heat from theworking fluid using the condenser 85. Thereafter, the cooled andexpanded working fluid may be directed through a conduit to return tothe reservoir 20 (FIG. 7A).

Still referring to FIGS. 7A-B, the fluid expansion system 10 may beequipped with a dual control valve system 70 that provides flow controlduring transient flow conditions, protection for the turbine generatorapparatus 100, and efficient power output from the turbine generatorapparatus 100. In this embodiment, the dual control valve system 70includes a first valve 72 a that operates as a through-flow valve to theturbine generator apparatus 100 and a second valve 72 b that operates asa bypass valve. The first and second valves 72 a-b can be actuated sothat one is fully open while another is fully closed. For example, whenthe system 10 is started so that the working fluid is initially beingheated by the heat source 60, the second valve 72 b (e.g., the bypassvalve) may be fully opened while the first valve 72 a may be fullyclosed. As such, the turbine generator apparatus 100 is not exposed tothe working fluid that is not fully heated to the desired temperature(e.g., some of which may still be in a liquid state), but the workingfluid is permitted to cycle through the bypass valve 72 b for repeatedheating cycles (e.g., the condenser 85 may be set to remove little ornot heat from the working fluid during this “cooking up” process).Continuing with this example, when the working fluid is thoroughlyheated to the desired temperature, the first valve 72 a may be set tofully open while the second valve is fully closed. In thesecircumstances, the bypass valve 72 b is closed and the heated andpressurized working fluid pass to the turbine generator apparatus 100 aspreviously described.

In some embodiments, the first and second valves 72 a-b of the dualcontrol valve system 70 may operate in unison so as to provideprotection for the turbine generator apparatus during transient flowconditions and to provide efficient power output from the turbinegenerator apparatus 100. In this embodiment, the first valve 72 a islinked to the second valve 72 b so that actuation of one valve resultsin actuation of the other. For example, the first valve 72 a and secondvalve 72 b may be coupled to the same actuator device (e.g., a servoactuator, a hydraulic actuator, a pneumatic actuator, a hand-operatedlever, or the like) so that a user can signal the actuator device toadjust the two valves 72 a-b in unison. In another example, the firstvalve 72 a may have a first actuator and the second valve 72 b may havea second actuator, both of which operate in response to control signalsfrom the same controller device. In some embodiments, one or both of thefirst and second valves 72 a-b may comprise actuator-controlledbutterfly valves that control the flow path of the working fluid (asdepicted, for example, in FIG. 2).

Referring now to some embodiments of the turbine generator apparatus100, the turbine generator apparatus 100 can generate kinetic energyfrom expansion of the working fluid. As previously described, the fluidexpansion system can be part of a closed system, such as a Rankine Cycleor the like, in which a pressurized and heated working fluid ispermitted to expand and release energy in the turbine generatorapparatus 100.

Referring to FIGS. 8-9, the heated and pressurized working fluid mayenter the turbine generator apparatus 100 through an inlet conduit 105and thereafter expand as the fluid flows over a rotatable turbine wheel120. In this embodiment, the working fluid is then directed to an outletside 125 (refer to FIG. 10) of the turbine wheel 120 so as to flowaxially through a body casing 107 and toward an outlet conduit 109. Theturbine wheel 120 can be configured to rotate as the working fluidexpands and flows toward the outlet side 125 of the turbine wheel 120.In this embodiment, the turbine wheel 120 is a shrouded turbine wheelthat includes a number of turbine blades 122 that translate the forcefrom fluid acting against the blades 122 into the rotational motion ofthe turbine wheel 120. In other embodiments, the shroud can be omittedand/or different configurations of turbine wheels can be used. Theworking fluid can flow through the turbine wheel inlet 124 locatedproximate to an input side 126 (refer to FIG. 10) of the turbine wheel120, act upon the turbine blades 122, and exit to the outlet side 125 ofthe turbine wheel. For example, in this embodiment, the outlet side 125of the turbine wheel 120 includes the region extending from proximatethe outlet face of the turbine wheel 120 and toward the outlet conduit109.

In some embodiments, the turbine wheel 120 is shaft mounted and coupledto a rotor 140. The rotor 140 may include a magnet 150. As such, theturbine wheel 120 is driven to rotate by the expansion of the workingfluid in the turbine generator apparatus 100, and the rotor 140(including the magnet 150) rotate in response to the rotation of theturbine wheel 120. In certain embodiments, the turbine wheel 120 isdirectly coupled to the rotor 140, for example, by fasteners, rigiddrive shaft, welding, or other manner. In certain embodiments, theturbine wheel 120 can be indirectly coupled to the rotor 140, forexample, by a gear train, cutch mechanism, or other manner.

As shown in FIGS. 8-9, two bearing supports 115 and 145 are arranged torotatably support the turbine wheel 120 relative to the body casing 107.In certain embodiments, one or more of the bearing supports 115 or 145can include ball bearings, needle bearings, magnetic bearings, journalbearings, or other. For example, in this embodiment, the first andsecond bearing supports 115 and 145 comprise magnetic bearings havingoperability similar to those described in U.S. Pat. No. 6,727,617assigned to Calnetix Inc. The disclosure of U.S. Pat. No. 6,727,617describing the features and operation of magnetic bearing supports isincorporated by reference herein. The first bearing support 115 ismounted to a frame structure 116 on the input side 126 of the turbinewheel 120, and the second bearing support 145 is mounted to a secondframe structure 146 on the outlet side 125 of the turbine wheel 120. Insuch circumstances, the turbine wheel 120 and the rotor 140 may beaxially aligned and coupled to one another so as to collectively rotateabout the axis of the bearing supports 115 and 145. Accordingly, boththe turbine wheel 120 and the rotor 140 can be supported in anon-cantilevered manner by the first and second bearing supports 115 and145.

In the embodiments in which the first and second bearing supports 115and 145 comprise magnetic bearings, the turbine generator apparatus 100may include one or more backup bearing supports. For example, the firstand second bearing supports 115 and 145 may comprise magnetic bearingsthat operate with electrical power. In the event of a power outage thataffects the operation of the magnetic bearing supports 115 and 145,first and second backup bearings 119 and 149 may be employed torotatably support the turbine wheel 120 during that period of time. Thefirst and second backup bearing supports 119 and 149 may comprise ballbearings, needle bearings, journal bearings, or the like. In thisembodiment, the first backup bearing support 119 includes ball bearingsthat are arranged near the first magnetic bearing support 115. Also, thesecond backup bearing support 149 includes ball bearings that arearranged near the second magnetic bearing support 145. Thus, in thisembodiment, even if the first and second bearing supports 115 and 149temporarily fail (e.g., due to an electric power outage or otherreason), the first and second backup bearing supports 119 and 149 wouldcontinue to support both the turbine wheel 120 and the rotor 140 in anon-cantilevered manner.

Still referring to FIGS. 8-9, some embodiments of the turbine generatorapparatus 100 may be configured to generate electricity in response tothe rotation of the driven member 150. For example, as previouslydescribed, the magnet 150 may comprise a permanent magnet that rotateswithin an electric generator device 160. The electric generator device160 may include a stator 162 in which electrical current is generated bythe rotation of the magnet 150 therein. For example, the stator 162 mayinclude a plurality of a conductive coils used in the generation ofelectrical current. The stator 162 and other components of the electricgenerator device 160 may produce heat as a byproduct during thegeneration of electrical current. As described in more detail below, atleast some of the heat byproduct can be dissipated by flow of theworking fluid exiting to the outlet side 125 of the turbine wheel 120.The electrical power generated by the rotation of the magnet 150 withinthe stator 162 can be transmitted to a generator electronics packagearranged outside of the body casing 107. In some embodiments, theelectrical power from the stator 162 can be directed to one or moreelectrical connectors 167 for transmission to the electronics package,which then configures the electrical power to selected settings. Thepower output can be configured to provide useable electrical power,including either AC or DC power output at a variety of voltages. In oneexample, the generator electronics package may be used to output a3-phase 60 Hz power output at a voltage of about 400 VAC to about 480VAC, preferably about 460VAC. In a second example, the generatorelectronics package may be used to output a DC voltage of about 12 V toabout 270 V, including selected outputs of 12 V, 125 V, 250 V, and 270V. In alternative embodiments, the electrical power output may beselected at other settings, including other phases, frequencies, andvoltages. Furthermore, the turbine generator apparatus 100 can be usedto generate power in a “stand alone” system in which the electricalpower is generated for use in an isolated network (e.g., to power anisolated machine or facility) or in a “grid tie” system in which thepower output is linked or synchronized with a power grid network (e.g.,to transfer the generated electrical power to the power grid).

The turbine generator apparatus 100 may include a number oflongitudinally extending fins 170. The fins 170 may support the stator162 in relation to the rotor 140 and direct the working fluid axiallythrough the body casing 107. For example, the working fluid can exit tothe outlet side 125 of the turbine wheel 120 and be directed by acontoured surface 142 of the rotor 140 toward the longitudinal fins 170.In some circumstances, the longitudinal fins 170 may serve as coolingfins that shunt at least a portion of the heat byproduct from the stator162 to the longitudinal fins 170 for subsequent heat dissipation by thefluid flow. As the working fluid flows along the longitudinal fins 170,the working fluid passes along components of the electrical generatordevice 160 so as to dissipate heat therefrom. In this embodiment, theworking fluid is directed to flow over the stator 162, as well as,between the stator 162 and rotor 140. The electrical generator device160 may include a number of electronic components (including the stator162) that produce significant heat during operation, so dissipation ofsuch heat can reduce the likelihood of component failure. As shown inFIGS. 8-9, because the permanent magnet 150 and the electrical generatordevice 160 are arranged on the outlet side 125 of the turbine wheel 120,the working fluid that exits the turbine wheel 120 can be used to coolthe components of the electrical generator device 160, thereby reducingthe need for an external cooling system for the electrical generatordevice 160.

Referring now to the turbine generator apparatus 100 in more detail asshown in FIG. 10, the inlet conduit 105 can be a tubular structure thatreceives the heated and pressurized working fluid and directs theworking fluid toward the input side 126 of the turbine wheel 120. Theinlet conduit 105 can be mounted to the body casing 107 using a numberfasteners that extend through adjacent flange portions. As such, theinlet conduit 105 can be removed from the body casing 107 so as toaccess the components on the input side 126 of the turbine wheel 120.For example, the inlet conduit 105 can be removed to provide serviceaccess to components such as a flow diverter cone 110, the first bearingsupport 115, and the first backup bearing support 119 that are disposedon the input side 126 of the turbine wheel 120. As described below, suchaccess can be achieved without necessarily removing the turbine wheel120 from the turbine apparatus 100.

The flow diverter cone 110 is arranged to extend into a portion of theinlet conduit 105 so as to direct the working fluid toward the turbinewheel inlet 124 disposed near the input side 126 of the turbine wheel120. The flow diverter cone 110 may include a number of pre-swirl vanes112 that impose a circumferential flow component to the inlet fluidflow. As such, when the working fluid flows into the turbine wheel inlet124, the flow may have a circumferential swirl component that is atleast partially similar to the rotational direction of the turbine wheel120. In some embodiments, the pre-swirl vanes 112 may be fixedly mountedto the flow diverter cone 110 at a predetermined angle so as to providethe desired tangential flow component. Alternatively, the pre-swirlvanes 112 can be adjustably mounted to the flow diverter cone 110 sothat the angle of the vanes 112 can be adjusted (e.g., by movement of anactuator 163, such as a hydraulic or electrical actuator coupled to thevanes 112) to vary the pre-swirl angle of all vanes 112 in unisonaccording to varying fluid flow conditions. In certain embodiments, theflow diverter cone 110 can house elements of the system, for example,one or more actuators 163 and other components. Although the pre-swirlvanes 112 are depicted as being mounted to the diverter cone 110 in thisembodiment, the pre-swirl vanes 112 can be fixedly mounted or adjustablymounted to the inlet conduit 105 near an inducer channel 117 to providethe desired tangential flow of the working fluid.

Still referring to FIG. 10, the working fluid flows from the pre-swirlvanes 112 and into the inducer channel 117 that directs the workingfluid toward the turbine wheel inlet 124. In this embodiment, theturbine wheel inlet 124 is a radial inflow inlet disposed near the inputside 126 of the turbine wheel 120. As such, the inducer channel 117 maydirect the working fluid to flow radially toward the turbine wheel inlet124 (with the tangential flow component imposed by the pre-swirl vanes112). The working fluid may pass through an inlet nozzle device 118 thatborders the periphery of the turbine wheel inlet 124. The inlet nozzledevice 118 may have adjustable inlet nozzle geometry in which the inletnozzle can be adjusted by one or more actuators. As previouslydescribed, the flow diverter cone 110 can be accessed for service ormaintenance by removing the inlet conduit 105 (without necessarilyremoving the turbine wheel 120). Similarly, the inlet nozzle device 118can be accessed for service or maintenance by removing the inlet conduit105 and the first frame structure 116 (again, without necessarilyremoving the turbine wheel 120).

When the working fluid flows into the turbine wheel inlet 124, theworking fluid acts upon the turbine blades 122 so as to impose arotational force upon the turbine wheel 120. In particular, the turbinewheel 120 that rotates about the wheel axis as the working fluid expandsand flows toward the outlet side 125 of the turbine wheel 120. Forexample, in some embodiments that employ an engineered fluid for use inan organic Rankine cycle, the working fluid may be pressurized andheated (in this example, to a temperature of about 230° F.) as it entersthe inlet conduit 105 and thereafter may expand as it flows over theturbine wheel 120 and exits to the outlet side 125 (in this example, ata temperature of about 120° F.). In alternative embodiments, thetemperatures of the working fluid in the pressurized and heated stateand the expanded state may be different from the previous example. Inparticular, the working fluid temperatures in the pressurized and heatedstate and in the expanded state may be selected based on a number offactors, such as the specific application in which the turbine generatorapparatus 100 is used, the properties of the working fluid, and thelike. At least a portion of the energy released from the expansion ofthe working fluid can be converted into kinetic energy in the form ofrotation of the turbine wheel 120. As previously described, in thisembodiment, the turbine wheel 120 is a shrouded turbine wheel thatincludes a number of turbine blades 122 that translate the force fromthe working fluid acting against the blades 122 into the rotationalmotion of the turbine wheel 120. The turbine blades 122 can extendedfrom the contoured hub of the turbine wheel 120 to the wheel shroud 123and may be angled or contoured so as to impose a rotational force on theturbine wheel 120 as the working fluid acts against the blades 122.

Still referring to FIG. 10, the working fluid can flow through theturbine wheel inlet 124 located proximate to the input side 126 of theturbine wheel, act upon the turbine blades 122, and exit to the outletside 125 of the turbine wheel 120 (e.g., the region extending fromproximate the outlet face of the turbine wheel 120 and toward the outletconduit 109). The turbine wheel 120 can be arranged in the turbinegenerator apparatus 100 so that the driven member 150 is on the outletside 125 of the turbine wheel 120 (rather than on the input side 126 ofthe turbine wheel 120). In such embodiments, the outlet flow of workingfluid to the outlet side 125 of the turbine wheel 120 is directed towardthe rotor 140 and the driven member 150. Such an arrangement of theturbine wheel 120 and the driven member 150 may provide a number offeatures that are useful in the construction, operation, and maintenanceof the turbine generator apparatus 100.

For example, in some embodiments, the arrangement of the turbine wheel120 permits the turbine wheel 120 to be supported by bearing supportsboth the input side 126 and the outlet side 125 (e.g., including theregion extending toward the outlet conduit 109). As previouslydescribed, the turbine wheel 120 can be rotationally supported by thefirst bearing support 115 (FIG. 10 and FIG. 9) and the second bearingsupport 145 (FIG. 9). The first bearing support 115 is arranged on theinput side 126 of the turbine wheel 120 so as to support the turbinewheel 120 relative to the first frame structure 116 and the body casing107 of the turbine generator apparatus 100. As such, the turbine wheel120 can rotate about the axis of the first bearing support 115. In thisembodiment, the turbine wheel 120 is not necessarily overhung from thefirst bearing support 115 in a cantilever fashion (e.g., with no bearingsupport on the one of the turbine wheel). Rather, in this embodiment,the second bearing support 145 (FIG. 2) is arranged on the outlet side125 of the turbine wheel 120 (here, residing at an end of the rotor 140opposite the turbine wheel 120 and within the region extending towardthe outlet conduit 109) so as to support the turbine wheel 120 relativeto the second frame structure 146 and the body casing 107 of the turbinegenerator apparatus 100. Accordingly, the turbine wheel 120 can berotatably mounted between the first bearing support 115 on the inputside 126 and the second bearing support 145 on the outlet side 125 ofthe turbine wheel 120. In such circumstances, the turbine wheel 120 (andthe rotor 140 in this embodiment) can be supported in a non-cantileveredfashion.

Such a configuration of the bearing supports 115 and 145 on both theinput side 126 and the outlet side 125 of the turbine wheel can providean environment that is favorable to rotordynamic operation andlubrication. For example, employing bearing supports on opposing sidesof the turbine wheel 120 may provide more uniform lubrication and loaddistribution along the rotational interfaces of the bearing supports (ascompared to an overhung turbine wheel that is cantilevered from abearing support). In addition, such a configuration can improvetemperature control of the rotational interfaces. Further, thearrangement of the turbine wheel 120 in the turbine generator apparatus100 can reduce the time and disassembly operations normally required forinspection and service of the bearing supports. For example, the bearingsupports 115 and 145 can be accessed for inspection and servicingwithout necessarily removing the turbine wheel 120 from the turbineapparatus 100. As shown in FIG. 10, the first bearing support 115 (and,in this embodiment, the first backup bearing support 119) can be readilyaccessed by removing the inlet conduit 105 and the flow diverter cone110 while the turbine wheel 120 remains generally in place. Because theinlet conduit 105 and flow diverter cone 110 can be comparativelysmaller and lighter weight than conventional cast scrolls, it is easierto access the turbine wheel 120 and first bearing supports 115. As shownin FIG. 9, the second bearing support 145 can be readily accessed byremoving the outlet conduit 109 and a cap portion of the second framestructure 146 (again, while the turbine wheel 120 remains generally inplace).

Still referring to FIG. 10, the arrangement of the turbine wheel 120 inthe turbine generator apparatus 100 permits the fluid outflow to theoutlet side 125 of the turbine wheel to be directed toward the stator162, rotor 140, and/or other components. As such, the working fluid canbe used as a heat dissipation flow after it has expanded (and therebycooled). For example, the working fluid can dissipate heat from theelectrical generator device 160, including the stator 162 and othercomponents.

As shown in FIG. 10, the working fluid exits the turbine wheel 120 intoan exhaust conduit 130, which includes a contoured surface to guide theexpanded working fluid. The fluid flow that exits to the outlet side 125of the turbine wheel 120 may be directed in a generally axial directiontoward the rotor 140 and stator 162, which are arranged along the outletside 125 of the turbine wheel 120. In some embodiments in which thestator 162 is to be cooled, at least a portion of the flow of theworking fluid may continue in the generally axial direction so as toflow directly over the stator 162 (e.g., along the outside of the stator162 and along the longitudinal fins 170). In some embodiments in whichthe rotor 140 is to be cooled, at least a portion of the flow of theworking fluid may continue in the generally axial direction so as toflow between the rotor 140 and the stator 162. Accordingly, some or allof the working fluid can be directed to flow over and dissipate heatfrom components of the electrical generator device 160. The rotor 140may include a contoured surface 142 that redirects some or all of thefluid flow at least partially in a radial direction toward thelongitudinal fins 170, which then guide the working fluid at leastpartially in an axial direction. Thus, some or all of the working fluidcan be directed by the contoured surface 142 and the exhaust conduit 130so as to flow over particular components of the electrical generatordevice 160.

Such an arrangement of the driven member 150 on the outlet side 125 ofthe turbine wheel 120 facilitates the use of the expanded working fluidas a heat dissipation medium. In some circumstances, the heatdissipation flow provided by the expanded working fluid may reduce oreliminate the need for an external cooling system for the rotor 140and/or stator 162 (and other components of the electrical generatordevice 160). For example, the expanded working fluid may flow along thelongitudinal fins 170 at a rate so as to cool the stator 162 withoutemploying an external cooling system to remove heat from the stator 162.

Still referring to FIG. 10, the arrangement of the turbine wheel 120 inthe turbine generator apparatus 100 provides for the use of seals 113and 133, which can serve to inhibit leakage of the working fluid out ofthe flow path. In addition, the arrangement of the turbine wheel 120permits the seals 113 and 133 to be readily accessed for inspection andservice. As shown in FIG. 10, the first seal 113 can be disposed on theinput side 126 along an outer annular surface of the turbine wheel 120.The first seal 113 can inhibit leakage of working fluid passing from thenozzle device 118 to a reaction pressure reservoir 137, and such leakagereduction can be used to direct the working fluid to the wheel inlet124. The second seal 133 can be disposed near the outlet side 125 of theturbine wheel along an outer annular surface of the wheel shroud 123.The second seal 133 can inhibit leakage of working fluid passing fromthe nozzle device 118 to the exhaust conduit 130, and such leakagereduction can be used to reduce the likelihood of the working fluidbypassing the wheel inlet 124. One or both of the first and second seals113 and 133 can be continuous-ring seals that are unitary andcircumscribe the turbine wheel 120. One or both may additionally, oralternatively, be labyrinth seals and may comprise a polymer material.In this embodiment, the first and second seals 113 and 133 haveidentical configurations.

In certain embodiments, the turbine wheel 120 can be pressure balanced.For example, when the working fluid exits to the outlet side 125 of theturbine wheel 120, a low pressure region may be created near the turbinewheel outlet, which creates a thrust force is in the axial directiontoward the outlet side 125. To counter this low pressure region and theresulting thrust force, the reaction pressure reservoir 137 is arrangedon the input side 126 of the turbine wheel 120. The reaction pressurereservoir 137 may be in fluid communication with the exhaust conduit 130so as to substantially equalize the pressure regions on both sides ofthe turbine wheel 120, thereby providing a thrust balance arrangementfor the turbine wheel 120.

For example, as the turbine wheel 120 operates, a small amount ofworking fluid may seep into the reaction pressure reservoir 137 (e.g.,some fluid may seep along the dynamic seal surface of the first seal113). As shown in FIG. 10, in response to lower pressure near theturbine wheel outlet, the pressure in the reservoir 137 may be reducedby directing the working fluid in the reaction pressure reservoir 137into a first channel 135 to a region on the interior of the flowdiverter cone 110. This region is in fluid communication with a secondconduit 111 (e.g., shown as an external piping arrangement) that extendstoward the exhaust conduit 130. Accordingly, the fluid pressure in thereaction pressure reservoir 137 may be equalized with the fluid pressurenear the turbine wheel outlet in the exhaust conduit 130, therebyneutralizing the thrust force that may other occur if the pressure onnear the turbine wheel outlet was substantially different from thepressure in the reservoir 137. Such a balancing of the thrust loadimposed upon the turbine wheel 120 may permit a substantial increase thepermissible pressure drop across the turbine wheel 120, which canthereby increase the maximum kinetic energy generated by the rotation ofthe turbine wheel 120.

It should be understood that, in other embodiments, the reactionpressure reservoir 137 may be in fluid communication with the exhaustconduit 130 via internal channels through the first frame member 116 andthe exhaust conduit (rather than using the external piping of the secondconduit 111). For example, the first channel 135 may be in fluidcommunication with a second channel bored partially through the firstframe structure 116 and partially through the wall of the exhaustconduit 130. In such circumstances, the reaction pressure reservoir 137can be in fluid communication with the exhaust conduit 130 so as tosubstantially equalize the pressure regions on both sides of the turbinewheel 120.

Still referring to FIG. 10, the arrangement of the turbine wheel 120 inthe turbine generator apparatus 100 can reduce the likelihood of leakageto or from the external environment. For example, because the flow fromthe outlet of the turbine wheel 120 is maintained within the turbinegenerator apparatus 100 rather than being exhausted outside of thesystem, the housing of the turbine generator apparatus 100 (includingbody casing 107) can be more readily hermetically sealed from the inletconduit 105 to the outlet conduit 109. Moreover, seepage of workingfluid to the input side 126 of the turbine wheel 120 can simply reenterthe working fluid flow path rather than leaking into the environment.For example, in the embodiment depicted in FIG. 10, the working fluidflows through the inlet nozzle 118 to the turbine wheel 120. As such,any leakage of the working fluid toward the input side 126 of theturbine wheel 120 would merely migrate into the reservoir 137. The fluidthat seeps into the reservoir 137 can readily reenter into the workingfluid flow path via the first and second conduits 135 and 111 (returningto the flow path near the exhaust conduit 130). In such circumstances,the working fluid that was leaked to the input side 126 of the turbinewheel 120 can reenter the flow of the working fluid without seeping intothe external environment (e.g., outside the inlet conduit 105, the bodycasing 107, or flow path piping).

Thus, such an arrangement of the turbine wheel 120 can provide ahermetically sealed turbine generator apparatus 100. Some embodiments ofthe hermetically sealed turbine generator apparatus 100 may be useful,for example, when the working fluid is a regulated or hazardous fluidthat should not be released into the external environment. In somecircumstances, the regulated or hazardous fluids may include engineeredfluids that are used in a number of organic Rankine cycles. For example,certain embodiments may use GENETRON 245fa, a product of HoneywellInternational, Inc., as a working fluid. In alternative embodiments, theworking fluid may comprise other engineered materials. Accordingly, theturbine generator apparatus 100 can be employed in an organic Rankinecycle so as to reduce the likelihood of leaking the working fluid intothe surrounding environment.

Referring now to FIG. 11, some embodiments of the turbine generatorapparatus 100 can be used in a Rankine cycle 200 that recovers wasteheat from one or more industrial processes. For example, as previouslydescribed, the Rankine cycle 200 may comprise an organic Rankine cyclethat employs an engineered working fluid to receive heat from anindustrial application including, but not limited to, commercial exhaustoxidizers (e.g., a fan-induced draft heat source bypass system, a boilersystem, or the like), refinery systems that produce heat, foundrysystems, smelter systems, landfill flare gas and generator exhaust,commercial compressor systems, food bakeries, and food or beverageproduction systems. As such, the turbine generator apparatus 100 can beused to recover waste heat from industrial applications and then toconvert the recovered waste heat into electrical energy. Furthermore,the heat energy can be recovered from geo-thermal heat sources and solarheat sources. In some circumstances, the working fluid in such a Rankinecycle 200 may comprise a high molecular mass organic fluid that isselected to efficiently receive heat from relatively low temperatureheat sources. Although the turbine generator apparatus 100 and othercomponents are depicted in the Rankine cycle 200, it should beunderstood from the description herein that some components that controlor direct fluid flow are excluded from view in FIG. 11 for illustrativepurposes.

As previously described, in particular embodiments, the turbinegenerator apparatus 100 can be used to convert heat energy from a heatsource into kinetic energy (e.g., rotation of the rotor 140), which isthen converted into electrical energy. For example, the turbinegenerator apparatus 100 may output electrical power that is configuredby an electronics package to be in form of 3-phase 60 Hz power at avoltage of about 400 VAC to about 480 VAC. As previously described,alternative embodiments may out electrical power having other selectedsettings. In some embodiments, the turbine generator apparatus 100 maybe configured to provide an electrical power output of about 2 MW orless, about 50 kW to about 1 MW, and about 100 kW to about 300 kW,depending upon the heat source in the cycle and other such factors.Again, alternative embodiments may provide electrical power at otherWattage outputs. Such electrical power can be transferred to a powerelectronics system and, in some embodiments, to an electrical power gridsystem. Alternatively, the electrical power output by the turbinegenerator apparatus 100 can be supplied directly to an electricallypowered facility or machine.

Similar to previously described embodiments, the Rankine cycle 200 mayinclude a pump device 210 that pressurizes the working fluid. The pumpdevice 210 may be coupled to a reservoir 212 that contains the workingfluid, and a pump motor 214 can be used to pressurize the working fluid.The pump device 210 may be used to convey the working fluid to a heatsource 220 of the Rankine cycle 200. As shown in FIG. 11, the heatsource 220 may include heat that is recovered from an existing process(e.g., an industrial process in which heat is byproduct). Examples ofsuch an industrial process include commercial exhaust oxidizers (e.g., afan-induced draft heat source bypass system, a boiler system, or thelike) or commercial compressor systems (e.g., commercial compressorinterstage cooling). In such circumstances, the working fluid may bedirectly heated by the existing process or may be heated in a heatexchanger in which the working fluid receives heat from a byproductfluid of the existing process. In this embodiment, the working fluid cancycle through the heat source 220 so that a substantial portion of thefluid is converted into gaseous state. Accordingly, the working fluid ispressurized by the pump device 210 and then heated by the heat source220.

Still referring to FIG. 11, the pressurized and heated working fluid maypass from the heat source 220 to the turbine generator apparatus 100.Similar to previously described embodiments, dual control valves 222 a-bmay be employed to control the flow of the working fluid to the turbinegenerator apparatus 100 (or to bypass the turbine generator apparatus100). For example, the first valve 222 a may be fully open while thesecond valve 22 b is fully closed, or vice versa. As previouslydescribed in connection with FIGS. 7A-B, the first and second controlvalves 222 a-b may be mechanically coupled to one another so as tooperate in unison. As such, an actuator device 224 may be activated by auser or by a computer control system to contemporaneously adjust thefirst valve 222 a and the second valve 222 b between the respectiveopened and closed positions.

When the first control valve 222 a is opened, the heated and pressurizedworking fluid may be directed to the liquid separator 40 (FIGS. 1 and4A). As previously described, the liquid separator 40 may be arrangedupstream of the turbine generator apparatus 100 so as to separate andremove a substantial portion of any liquid state droplets or slugs ofworking fluid that might otherwise pass into the turbine generatorapparatus 100. Accordingly, the gaseous state working fluid can bepassed to the turbine generator apparatus 100 while a substantialportion of any liquid-state droplets or slugs are removed and returnedto the reservoir 212.

After passing through the liquid separator 40, the heated andpressurized working fluid may pass through the inlet conduit 105 andtoward the turbine wheel 120 (FIG. 8). As previously described inconnection with FIGS. 8-10, the working fluid expands as it flows acrossthe turbine wheel 120 and into the body casing 107, thereby acting uponthe turbine wheel 120 and causing rotation of the turbine wheel 120.Accordingly, the turbine generator apparatus 100 can be included in afluid expansion system in which kinetic energy is generated fromexpansion of the working fluid. The rotation of the turbine wheel 120 istranslated to the rotor 140, which in this embodiment includes themagnet 150 that rotates within an electrical generator device 160 (FIGS.8-10). As such, the kinetic energy of the turbine wheel 120 is used togenerate electrical energy. As previously described, the electricalenergy output from the electrical generator device 160 can betransmitted via one or more connectors 167 (e.g., three connectors 167are employed in this embodiment).

Still referring to FIG. 11, in some embodiments, the electrical energycan be communicated via the connectors 167 to a power electronics system240 that is capable of modifying and storing the electrical energy. Inone example, the power electronics system 240 may be similar to powersubstation that is connected to an electrical power grid system. Aspreviously described, in some embodiments, the turbine generatorapparatus 100 may be configured to provide an electrical power output ofabout 2 MW or less, about 50 kW to about 1 MW, and about 100 kW to about300 kW, depending upon the heat source 220, the expansion capabilitiesof the working fluid, and other such factors. As an alternative to theembodiment depicted in FIG. 11, the electrical energy output by theturbine generator apparatus 100 can be supplied directly to anelectrically powered facility or machine.

In some embodiments of the Rankine cycle 200, the working fluid may flowfrom the outlet conduit 109 of the turbine generator apparatus 100 to acondenser 250. The condenser 250 may include a motor 252 that is used toremove excess heat from the working fluid so that a substantial portionof the working fluid is converted to a liquid state. For example, themotor 252 may be used to force cooling airflow over the working fluid.In another example, the motor 252 may be used to force a cooling fluidto flow in a heat exchange process with the working fluid. After theworking fluid exits the condenser 250, the fluid may return to thereservoir 212 where it is prepared to flow again though the cycle 200.

Referring to FIG. 12, in one example, the working fluid that passesthrough the turbine generator apparatus 100 may recover waste heat froma commercial compressor interstage cooling process. A commercialcompressor process may employ interstage cooling in which the compressorfluid is cooled in a heat exchanger between one or more of thecompression stages. In such circumstances, the commercial compressorinterstage cooling may serve as the heat source 60 (FIG. 4A) or 220(FIG. 11) for the working fluid in the Rankine cycle.

In this embodiment, the commercial compressor may include a plurality ofcompressor stages 310, 320 and 330. A first heat exchanger 315 may bearranged between the first and second compressor stages 310 and 320 soas to remove heat from the compressor fluid. The working fluid of theRankine cycle passes through a first section 316 of the heat exchanger315 to receive a portion of the heat dissipated from the compressorfluid flow. In some circumstances, the compressor fluid may requirefurther cooling, so a coolant fluid may pass through a second section318 of the heat exchanger 315 to further dissipate any excess heat fromthe compressor fluid. After removing the excess heat from the compressorfluid, the coolant fluid may be directed to a cooling tower or the like.As shown in FIG. 12, the first section 316 and the second section 318may be isolated from one another so that the working fluid of theRankine cycle receives the heat from the compressor fluid as itinitially exits from the first compressor stage 310. The first andsecond sections 316 and 318 of the heat exchanger 315 can beindependently controlled. As such, the flow of the coolant fluid throughthe second section 318 can be adjusted to increase or decrease theoverall amount of heat that is removed from the compressor fluid,thereby providing fine tuned control of the compressor fluid temperaturewhile enabling the working fluid of the Rankine cycle to receive asubstantial amount of heat.

Still referring to FIG. 12, the working fluid that is heated in thefirst heat exchanger 315 may be directed to a second heat exchanger 325arranged between the second compressor stage 320 and the thirdcompressor stage 330. Similar to the first heat exchanger 315, thesecond heat exchanger 325 may be subdivided into two sections 326 and328. The working fluid of the Rankine cycle passes through the firstsection 326 of the heat exchanger 325 to receive a portion of the heatdissipated from the compressor fluid flow after the second compressorstage 320. The coolant fluid may pass through a second section 318 ofthe heat exchanger 325 to further dissipate any excess heat from thecompressor fluid. Again, after receiving any excess heat from thecompressor fluid after the second compressor stage 320, the coolantfluid may be directed to a cooling tower or the like. Similar to thepreviously described heat exchange 315, the first section 326 and thesecond section 328 of the second heat exchanger 325 may be isolated fromone another so that the working fluid of the Rankine cycle receives theheat from the compressor fluid as it initially exits from the secondcompressor stage 320.

Accordingly, the working fluid of the Rankine cycle can be incrementallyheated by a series of heat exchangers 315 and 325 arranged after thecompressor stages 310 and 320 of a commercial compressor interstagecooling process. Such a process permits the waste heat from anindustrial process to be recovered and converted into electrical energy(e.g., by expansion of the working fluid in the turbine generatorapparatus 100). In some circumstances, the electrical energy generatedby the turbine generator apparatus 100 can be used to at least partiallypower the industrial process that generates the heat (e.g., theelectrical power can be used to at least partially power the commercialcompressor system). Moreover, in alternative embodiments, the kineticenergy from the rotation of the turbine wheel 120 in the turbinegenerator apparatus 100 can be used to mechanically power the commercialcompressor system. For example, the turbine wheel 120 in the turbinegenerator apparatus 100 can be coupled to at least one of the compressorhigh-speed shafts to augment the power required to rotate the compressorhigh-speed shaft (e.g., in a multi-stage turbo compressor application).Although the plurality of compressor stages 310, 320 and 330 can be usedto heat the working fluid in the Rankine cycle, it should be understoodthat (in other embodiments) only one of the compressor stages (e.g.,stage 310) may be used as the heat source for the working fluid.

The embodiments described in connection with FIG. 12 include thecommercial compressor interstage cooling process operating as the heatsource 60 (FIG. 4A) or 220 (FIG. 11) for the working fluid in theRankine cycle. It should be understood that, in some embodiments, theRankine cycle described in connection with FIG. 12 may employ a fluidexpansion system other than the previously illustrated fluid expansionsystem 10.

Referring to FIG. 13, in another example, the working fluid that passesthrough the turbine generator apparatus 100 may recover waste heat froman industrial process 420, such as a commercial exhaust oxidizer, inwhich heat is byproduct. Accordingly, the working fluid is pressurizedby the pump device 30 and then heated in a heat exchange process withthe high-temperature exhaust fluid of the industrial process 420 beforepassing to the turbine generator apparatus 100.

In this embodiment, the Rankine cycle 400 includes the fluid expansionsystem 10, the industrial process 420 in which heat is byproduct (e.g.,commercial exhaust oxidizer to the like), and a condenser 450 (e.g., anevaporative condenser or the like). The industrial process 430 mayinclude an exhaust stack 425 through which a heated exhaust fluid isexpelled. The heated exhaust fluid may be a byproduct of the industrialprocess 420. For example, in some oxidizer systems, the exhaust fluidmay pass into the exhaust stack 425 at a temperature of about 200° F. ormore, about 250° F. or more, about 300° F. to about 800° F., about 350°F. to about 600° F., and in some embodiments at about 400° F. Ratherthan allowing the heated exhaust fluid to be fully dissipated to theenvironment without recovering the heat energy, the Rankine cycle 400may incorporate the fluid expansion system 10 to recover at least aportion of the heat energy and generate electrical power therefrom. Forexample, the working fluid that passes that passes through the turbinegenerator apparatus 100 may be heated in a heat exchanger 427 arrangedproximate to the exhaust stack 425 of the industrial process 420. Thus,the exhaust stack 425 of the industrial process 420 may serve as anevaporator or other heat source that transfers heat energy to theworking fluid before the working fluid passes through the turbinegenerator apparatus 100. In this embodiment, the heat exchanger 427 isdisposed in the exhaust stack 427 so as to recover at least a portion ofthe heat energy from the exhaust fluid and to transfer that heat energyto the working fluid of the Rankine cycle 400.

Still referring to FIG. 13, the working fluid that is heated in the heatexchanger 427 may be directed to the fluid expansion system 10 forpassage through the liquid separator 40 and the turbine generatorapparatus 100. As previously described in connection with FIGS. 8-10,the turbine generator apparatus 100 can be used to generate electricalenergy from the heated and pressurized working fluid. Accordingly, theworking fluid of the Rankine cycle 400 can be heated by at least oneheat exchanger 427 arranged at the exhaust stack 425 of the industrialprocess 420 (e.g., a commercial exhaust oxidizer process). Such a cyclepermits the waste heat from an industrial process 420 to be recoveredand converted into electrical energy by expansion of the working fluidin the turbine generator apparatus 100. In some circumstances, theelectrical energy generated by the turbine generator apparatus 100 canbe used to at least partially power the industrial process thatgenerates the heat (e.g., the electrical power can be used to at leastpartially power the oxidizer system).

After the working fluid is expanded in the turbine generator apparatus100, the working fluid may be directed to a condenser unit 450 of theRankine cycle 400. The condenser unit 450 may comprise, for example, andevaporative condenser that outputs the working fluid in a cooled state(e.g., in a liquid state). The expanded and cooled working fluid is thendirected to the reservoir 20 of the fluid expansion system 10 where itawaits passage through the pump 30 and to the heat exchange process.This fluid cycle can be repeated so as to recover the waste heat fromthe industrial process 420 and thereafter convert the heat energy intoelectrical energy (e.g., by expansion of the working fluid in theturbine generator apparatus 100).

The embodiments described in connection with FIG. 13 include thecommercial exhaust oxidizer operating as the heat source 60 (FIG. 4A) or220 (FIG. 11) for the working fluid in the Rankine cycle. It should beunderstood that, in some embodiments, the Rankine cycle described inconnection with FIG. 13 may employ a fluid expansion system other thanthe previously illustrated fluid expansion system 10

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.Accordingly, other embodiments are within the scope of the followingclaims.

1. A method of using a turbine generator system, comprising: pumping aworking fluid in a Rankine cycle from a low pressure reservoir toward atleast one compressor interstage cooler; heating the working fluid fromheat energy recovered from one or more compression stages of thecompressor interstage cooler, at least a portion of the working fluidbeing pressurized and heated to a gaseous state; directing the heatedand pressurized working fluid toward a turbine generator apparatus, theturbine generator apparatus including an inlet conduit to direct theworking fluid toward a turbine wheel that is rotatable in response toexpansion of the working fluid; and generating electrical energy fromthe rotation of the turbine wheel, the turbine wheel being coupled to arotor of an electrical energy generator that rotates within a stator ofthe electrical energy generator.
 2. The method of claim 1, furthercomprising directing the working fluid toward one or more heatexchangers to heat the working fluid from the heat energy recovered fromat least two compression stages of the compressor interstage cooler. 3.The method of claim 1, further comprising separating a liquid stateportion of the heated and pressurized working fluid from a gaseous stateportion of the heated and pressurized working fluid before the workingfluid is delivered to the turbine generator apparatus.
 4. The method ofclaim 3, wherein the liquid state portion is separated using a cycloneseparator device, the cyclone separator device being arranged in theRankine cycle upstream of the turbine generator apparatus.
 5. The methodof claim 1, wherein the rotor of the electrical energy generator isarranged on an outlet side of the turbine wheel.
 6. The method of claim5, further comprising cooling at least a portion of the electricalenergy generator with the working fluid exiting to the outlet side ofthe turbine wheel.
 7. The method of claim 1, wherein the Rankine cycleis an organic Rankine cycle, and the working fluid comprises highmolecular mass organic fluid.
 8. The method of claim 7, furthercomprising cycling the working fluid through the organic Rankine cyclewhile inhibiting seepage of the working fluid to an environment externalto the organic Rankine cycle.
 9. The method of claim 1, furthercomprising transporting a system package that houses the turbinegenerator apparatus, a liquid separator, a fluid pump device, and thelow pressure reservoir for the working fluid, the system package havinga width of less than about 50 inches and a height of less than about 80inches so as to fit through a double-door passage.
 10. The method claimof claim 9, wherein the system package has a width of about 48 inches orless and a height of about 78 inches or less.
 11. The method of claim 1wherein the compressor interstage cooler is part of a commercialcompressor.
 12. A method of using a turbine generator system,comprising: pumping a working fluid in a Rankine cycle from a lowpressure reservoir toward at least one compressor interstage cooler;directing the working fluid toward one or more heat exchangers to heatthe working fluid from heat energy recovered from at least twocompression stages of the compressor interstage cooler; heating theworking fluid from the heat energy recovered from the at least twocompression stages of the compressor interstage cooler, at least aportion of the working fluid being pressurized and heated to a gaseousstate; directing the heated and pressurized working fluid toward aturbine generator apparatus, the turbine generator apparatus includingan inlet conduit to direct the working fluid toward a turbine wheel thatis rotatable in response to expansion of the working fluid; andgenerating electrical energy from the rotation of the turbine wheel, theturbine wheel being coupled to a rotor of an electrical energy generatorthat rotates within a stator of the electrical energy generator.
 13. Amethod of using a turbine generator system, comprising: cycling a highmolecular mass, organic working fluid in an organic Rankine cycle from alow pressure reservoir toward at least one compressor interstage cooler,the working fluid cycled through the organic Rankine cycle whileinhibiting seepage of the working fluid to an environment external tothe organic Rankine cycle; heating the working fluid from heat energyrecovered from one or more compression stages of the compressorinterstage cooler, at least a portion of the working fluid beingpressurized and heated to a gaseous state; directing the heated andpressurized working fluid toward a turbine generator apparatus, theturbine generator apparatus including an inlet conduit to direct theworking fluid toward a turbine wheel that is rotatable in response toexpansion of the working fluid; and generating electrical energy fromthe rotation of the turbine wheel, the turbine wheel being coupled to arotor of an electrical energy generator that rotates within a stator ofthe electrical energy generator.
 14. A Rankine cycle system, comprising:a pump device coupled to a low pressure reservoir and one or more heatexchangers to receive a working fluid in the Rankine cycle from the lowpressure reservoir and to pump the working fluid toward the one or moreheat exchangers; the one or more heat exchangers coupled to at least oneinterstage cooler to heat the working fluid from heat energy recoveredfrom one or more compression stages of the compressor interstage cooler,at least a portion of the working fluid being pressurized and heated toa gaseous state; and a turbine generator apparatus coupled to the one ormore heat exchangers for receiving heated and pressurized working fluid,the turbine generator apparatus comprising: a turbine wheel configuredto receive the heated and pressurized working fluid and rotate inresponse to expansion of the working fluid flowing from an inlet side toan outlet side of the turbine wheel, and an electric generator having astator and a rotor, the rotor coupled to the turbine wheel to rotatewithin the stator in response to rotation of the turbine wheel togenerate electrical energy.
 15. The system of claim 14 wherein the oneor more heat exchangers is coupled to the at least one interstage coolerto heat the working fluid from heat energy recovered from at least twocompression stages of the compressor interstage cooler.
 16. The systemof claim 14 further comprising a liquid separator configured to separatea liquid state portion of the heated and pressurized working fluid froma gaseous state portion of the heated and pressurized working fluid, theliquid separator arranged in the Rankine cycle upstream of the turbinegenerator apparatus.
 17. The system of claim 16, wherein the liquidseparator is a cyclone separator device, the cyclone separator devicebeing arranged in the Rankine cycle upstream of the turbine generatorapparatus.
 18. The system of claim 14, wherein the rotor of theelectrical energy generator is arranged on an outlet side of the turbinewheel.
 19. The system of claim 18, wherein the electric generator isconfigured to receive working fluid exiting the outlet side of theturbine wheel, the electric generator configured to direct the workingfluid between the rotor and the stator.
 20. The system of claim 14,wherein the Rankine cycle is an organic Rankine cycle, and the workingfluid comprises high molecular mass organic fluid.
 21. The system ofclaim 20 further configured to prevent seepage of the working fluid toan environment external to the organic Rankine cycle.
 22. The system ofclaim 14, further comprising a system package that houses the turbinegenerator apparatus, a liquid separator, the pump device, and the lowpressure reservoir for the working fluid, the system package having awidth of less than about 50 inches and a height of less than about 80inches so as to fit through a double-door passage.
 23. The system claimof claim 22, wherein the system package has a width of about 48 inchesor less and a height of about 78 inches or less.